Knuckle and bushing assembly

ABSTRACT

A suspension coupling for use in a vehicle suspension system the suspension coupling including a knuckle and bushing assembly wherein the knuckle member is a cast aluminum piece having a passage for receiving a two-piece bushing having a formed, metal inner member and a molded, elastomeric outer member having extension members at each end. The bushing member is press-fit into the knuckle member and exhibits higher stiffness in the radial and axial directions and lower stiffness in the torsional and conical directions.

CROSS REFERENCE TO RELATED APPLICATIONS

This application hereby claims priority to U.S. Provisional PatentApplication No. 61/360,214, filed Jun. 30, 2010, to Darcey-Sharma;titled Knuckle and Bushing Assembly, the entire contents of which isincorporated herein.

FIELD OF THE DISCLOSURE

This disclosure generally relates to an integrated bushing for use in asuspension component such as a clevis knuckle for use in the suspensionof a vehicle. More particularly, the present disclosure relates to anintegrated bushing for use in knuckle of a suspension of a vehicle, theintegrated bushing having improved performance, cost and othercharacteristics.

BACKGROUND

It is generally known for a vehicle to have a suspension system forproviding a level ride, for managing the pitch, roll and yaw of thevehicle as it travels across varying terrains and dampening or managingacceleration and deceleration of the suspension components in varyingoperating conditions. As part of the suspension system, it is also knownto generally utilize one or more structural attachment components (e.g.,a clevis and pin) for coupling one suspension component with anothersuspension component. Traditionally, such suspension components includea knuckle member having a passage therein for receiving a bushing forproviding stiffness and damping to the coupling between the suspensioncomponent having the knuckle member and the suspension component havingthe attachment component (e.g., clevis member). The suspension componentcoupling typically uses a pin, bolt or other coupling member forcoupling to the bushing member. Generally, the pin, bolt, or othermember is located in a hole in the bushing to transfer forces from theone suspension component to the bushing located in the passage in theknuckle member. The bushing between the stock member and the knucklemember must exhibit relatively very high performance characteristics fordampening the transfer of loads between the suspension components. Formany applications, it is important to have a knuckle—bushing arrangementthat has relatively low torsional and conical stiffness (e.g., so thatit affords suitable mobility of the suspension component) while havingrelatively high radial and axial stiffness (e.g., so that the bushingbetter transfers the loads between the suspension components). Theachievement of such characteristics without a complicated and/orexpensive structure has been difficult to achieve. Accordingly, thereremains a long-felt need to provide a suspension coupling with improvedcharacteristics that also preferably has relatively few components, arelatively low cost and improved other characteristics.

SUMMARY

In one exemplary embodiment, there is disclosed a suspension system foruse in a vehicle. The suspension system includes an integrated knuckleand bushing assembly having a knuckle member having a first passage forreceiving therein a bushing, the bushing is located within the firstpassage of the knuckle member and has an interference fit with the firstpassage. The bushing has a centrally located passage extending from afirst end of the bushing to a second end of the bushing. The bushingpassage (through which a suitable coupling member may be passed forattachment of a suspension component) defines an axis that issubstantially aligned with a center axis of the first passage of theknuckle member. In one exemplary embodiment, the bushing member has afirst, inner member having a shaped outer periphery and contains thecentrally located passage. The bushing member further includes a second,outer member having an annular, formed shape. The bushing memberincludes a pair of axially spaced apart ears for providing enhancedaxial stiffness and each ear has a pair of recesses or valleys on eachside of the ear for providing improved torsional and conical flexibilityto the bushing member. The ears and valleys extend annularly around theouter member. The outer member also has a center annular portion locatedbetween the ears for providing radial stiffness to the bushing member.

In one exemplary embodiment the knuckle member has a first extensionmember further defining the passage in the knuckle member and initiallylocated in an extended position wherein the first extension member is atleast partially extended in a direction generally aligned with thecenter axis of the first passage of the knuckle member and wherein thebushing member is located within the first passage of the knucklemember. In this embodiment, the bushing member is press fit within thepassage and is contained within the passage of the knuckle member by asecond end of the passage. Then the first extension member is formedfrom the extended position to a formed position (e.g., by bending,folding, or otherwise deforming) wherein the resulting deformed firstextension member of the knuckle member extends over at least a portionof a first end portion of the bushing member to secure the bushingmember within the first passage of the knuckle member (e.g., by forminga blocking structure).

In another exemplary embodiment, the second end of the passage of theknuckle member may also have a second extension member initiallyextending at least partially in a direction generally aligned with thecenter axis of the passage (which may also be in a directionsubstantially aligned of the first extension member prior todeformation). The second extension member maybe formed to a second orformed position in which the second extension member extends over atleast a portion of a second end portion of the bushing member such thatthe first and second extension members of the knuckle member secure thebushing member within the first passage of the knuckle member. Theknuckle member may be made from a metal material (e.g., a castaluminum-containing material such as an aluminum based alloy). Either orboth of the first and second extension members may be parent metalformed. In one exemplary embodiment, the bushing member is preferably anannular shaped, elastomeric body having a formed peripheral surface. Theformed peripheral surface of the bushing member may include one or more(and preferably two) generally annular and elastically deformable earstructures generally axially flanking a center portion of the bushingmember and, more particularly, offset distally from the center portionin a direction along the axis of the passage of the knuckle member). Thebushing member may be suitably dimensioned and shaped so that it can bepressed into the first passage in the knuckle member to have aninterference fit with an interior wall defining the first passage. Thebushing member may be dimensioned so that at least the central portionof the shaped elastomeric body is loaded in compression (e.g., radialcompression). The bushing member may include a two-piece, molded bodyhaving an outer portion produced from an elastomeric material and, inparticular, a material including, consisting essentially of, orconsisting of a natural rubber material. The bushing member, in anexemplary embodiment includes a second piece that is an inner or coremember having a through-hole and a shaped outer surface that isgenerally complementary in shape to the interior wall portion of thebushing member. For example, as with the shape of at least a portion ofthe interior wall portion, the shaped surface of the second piece mayinclude a central, rounded or substantially spherical-shaped portion. Itmay also include first and second shaped end portions. The first andsecond end portions of the core of the bushing member preferably eachhave a smaller or narrow portion closer to the central portion andgenerally may grow larger in diameter toward the ends of the bushingmember for providing a stronger bearing area for the pin. The shapedelastomeric body of the outer member, around the inner member, when thebushing member is press-fit into the passage in the knuckle member mayhave a section thickness at a central portion of the bushing member thatis less than preferably about 4 millimeters (mm) and may have a sectionthickness at the central portion that is between preferably about 2 and3 millimeters (mm). Further, the inner member preferably has first andsecond ends that each has a surface area sufficient for clamping by asuspension component such as a clevis pin. The inner member has avarying diameter annular shape having a larger diameter toward the firstand second ends and a reducing diameter as axially toward the centralportion where the diameter again becomes larger. This design provideslarger ends surface areas for the inner member while providing reducedthickness of the inner member to provide improved conical flexibility ofthe bushing member.

In one exemplary embodiment, the first or outer member of the bushingmember is a molded body that is injection molded over the second ormetal core of the bushing member. The core may include a through holefor coupling the bushing member to one suspension component.

The outer member of the bushing member may be formed to include at leastone or more car structures that generally circumscribe the annularshaped outer member. The ear structures may be designed to stiffen inresponse to an axial force or movement of the bushing member relative tothe knuckle member. The outer member may further include a reducedthickness portion on each side of the ear to form a pair of valleys thatallows freer torsional and conical movement of the bushing member withrespect to the knuckle member because there is no bushing membermaterial in those directions around the ear structure during operation.Accordingly, the ear structures are designed to stiffen in response toaxial forces applied to the bushing member during operation and theradial stiffness of the bushing member is improved by having the bushingmember press-fit into the knuckle member.

In one exemplary embodiment the knuckle and bushing assembly may includea bushing member having a generally annular exterior surfacecomplementary to the interior surface of the passage in the knucklemember and the exterior surface of the bushing member has a generallyuncompressed diameter that is slightly larger than the diameter of theinterior surface of the passage in the knuckle member such that thebushing member will have an interference fit in the passage. Theinterior surface of the passage of the knuckle member and the exteriorsurface of the bushing member may each have a substantially constantradius or rounded surface from one end to the other end; or a pluralityof surfaces each of different radii (e.g., the surface havingprogressively varying radii). In one exemplary embodiment, the interiorsurface of the passage of the knuckle member and the exterior surface ofthe bushing member each may have a generally linear surface fromsubstantially a first end to a second end. In one alternative exemplaryembodiment, the interior surface of the passage of the knuckle memberand the exterior surface of the bushing member each may have a generallynon-linear or curvilinear surface over at least a portion of the lengthfrom substantially a first end to a second end.

The knuckle and bushing assembly may have a generally annularintermediate or central portion for the elastomeric body that is loadedin compression in the passage of the knuckle member. Once the bushingmember is press-fit into the passage in the knuckle member to form theknuckle and bushing assembly, a central portion of the elastomeric outermember of knuckle member may have a radial section having a thickness ofless than about 4 millimeters (mm) and greater than about 1 millimeter(mm) during operation of the knuckle and bushing assembly. Further, theradial section of the annular elastomeric outer member of the bushingmember may have a thickness of about 2 to 3 millimeters (mm).

The knuckle and bushing assembly may include a knuckle member having anouter portion of the bushing having a pair of ears that each generallycircumscribe the bushing member and each of the ears have a contouredouter surface defining a generally circumscribing contoured recessedarea between the ears.

The knuckle and bushing assembly may further include at least onesuspension component selected from the group of a clevis, a control arm,a pin, a king pin, a stabilizer bar, a shock, or any other suspensionmember that may utilize a bushing and any combination thereof.

There is also disclosed a method for manufacturing the knuckle andbushing assembly for use in a suspension assembly in a vehicle includingthe steps of producing the knuckle member having a passage extendingthere through. The knuckle member is produced having a first extensionmember located at one end of the passage and further defining thepassage. At the same or different time a bushing is produced having apassage extending there through and the bushing is formed having aplurality of annular reduced portions located in the exterior surface ofthe bushing. The bushing is located within the passage of the knucklemember and is generally axially aligned in the passage in the knucklemember, the bushing for providing improved radial and axial stiffnessfor the suspension member to be coupled the knuckle member. Then thefirst extension member may be formed from its first position to a secondposition wherein it extends at least partially aligned offset with thecenter axis of the passage in the knuckle and the first extension memberextends over at least a portion of the bushing to couple and contain thebushing within the passage of the knuckle member. The knuckle member maybe produced to include a second extension member located at a second endof the passage. The second extension member may also be formed from afirst position to a second position to securely couple the bushingmember to the knuckle member. The second extension member may be formedas part of an initial cast structure.

The bushing member is produced as a two-piece construction wherein aninner member is produced from a metal, preferably steel, material in anyknown or appropriate process. In one exemplary embodiment the innermember is preferably a cold-formed member having a central portionhaving a generally spherical shape and conically shaped end portionswith a central through-hole. The inner member may be located in amolding machine and the outer member is over-molded onto the innermember and may be injection molded in one particular exemplaryembodiment. In one exemplary embodiment the inner member is first atleast partially covered (e.g., coated) with a suitable adhesion promoter(e.g., an adhesive, a primer or both) such as a phosphate-based primercoating for promoting adhesion of the elastomeric outer member to themetal inner member. After being casted, the knuckle member may bemachined to produce the first passage. The method for manufacturing anintegrated knuckle and bushing assembly may include assembling andlocating the bushing in radial compression, such as by press-fitting thebushing within the passage of the knuckle member prior to forming one orboth ends of the passage of the knuckle member to secure the bushingwithin the passage.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial, graphic side view of a suspension componentincluding a knuckle and bushing assembly according to an exemplaryembodiment;

FIG. 2 is a partial sectional, graphic view of the integrated knuckleand bushing assembly according to the present disclosure;

FIG. 3 is a partial sectional, graphic view of the knuckle memberdetailing a manufacturing step according to the present disclosure; and

FIG. 4 is a partial sectional, graphic view of the bushing memberlocated in the knuckle member detailing a manufacturing step accordingto the present disclosure.

DETAILED DESCRIPTION

A suspension system may be used in a vehicle for providing a level rideto the vehicle by managing the pitch, roll and yaw of the vehicle bydampening or managing acceleration and deceleration of the suspensioncomponents in varying operating conditions. The suspension systemtypically includes a plurality of suspension components such as acontrol arm, a pin, a king pin, strut, spring, shock absorber, steeringcomponent, wheel assembly component, mounting hardware and/or otherknown suspension. The suspension components may be coupled togetherusing any known or appropriate coupling components. In one particulartype of coupling a clevis and clevis pin may be used for coupling onesuspension component with another suspension component. In one exemplaryembodiment one suspension component may include the clevis and the othersuspension component may include a knuckle member that may be coupled tothe clevis using a clevis pin located in holes in each end of each armor prong of the clevis. The clevis pin may be secured to the clevisusing any known or appropriate fastener such as a nut on a threaded endof the clevis pin, similar to a bolt. In this type of suspensioncoupling, the knuckle member may include a passage or hole for receivingthe main portion of the clevis pin and thereby coupling the clevis tothe knuckle member.

In one exemplary embodiment according to the present disclosure asuspension coupling 5 may include a knuckle and bushing assembly 10located at a knuckle boss, as shown in FIGS. 1 and 2. The knuckle andbushing assembly 10 includes a knuckle member 12 and a bushing member(or hub) 15. The suspension coupling 5 is designed to provide a couplingthat exhibits a relatively high radial (R) and axial (A) stiffness alongwith a relatively low torsional (T) and conical stiffness (C) as shownby the directional arrows in FIG. 2 wherein the origin of thecoordinates is referenced and used herein as if it is located at thephysical center the knuckle suspension component 5 even though it is notshown that way in FIG. 2. The suspension coupling 5 is designed forcoupling one suspension component to another and for transfer of forcesbetween them. The suspension coupling 5 may be designed to haverelatively minimal relative movement between the suspension componentsof the suspension coupling 5. To the extent any movement occurs, it willbe generally a result of elastic deformation. The clevis (not shown) iscoupled to the knuckle member 12 by the clevis pin (not shown) todirectly transfer the forces applied to the one suspension componenthaving the clevis to clevis pin and then to the knuckle member 12.Accordingly the forces transferred between the components of thesuspension coupling 5 necessarily transfer through the bushing member15. The bushing member 15 provides improved axial and radial stiffness,improved torsional and conical flexibility characteristics for thesuspension coupling 5 while also having a lower cost and other improvedcharacteristics.

Knuckle Member

The knuckle member 12 has a generally round structure but may have anyappropriate shape for use in the suspension coupling 5. The knucklemember 12 has a wall defining a passage (or bore) 21 extending between afirst end or side 22 and a second end or side 23. The knuckle member 12is preferably produced as a cast aluminum metal piece using any known orappropriate casting parameters and production techniques. The walldefining the passage 21 of the knuckle member 12 is generally round andextends from the first end 22 to the second end 23 and may have aconstant radius or diameter. The wall defining the passage 21 may alsoalternatively have a generally non-linear or curved shape in crosssection from the first end 22 to the second end 23 (not shown) whereinthe radius (and therefore the diameter) of the passage 21 is smallest atthe first end 22 and the second end 23 and has a central portion 24 thatmay have a larger radius. The wall defining the passage 21 may alsoalternatively have a constantly changing radius (not shown) from thefirst end 22 to the central portion 24 or it may have varying rates ofchange including zero. The wall defining the passage 21 may be formedduring the casting process of producing the knuckle member 12 or may beformed afterward. The wall defining the passage 21 may be further formedby precision grinding or milling, or by using any other known orappropriate machining, cutting or forming process.

The knuckle member 12 and the wall defining the passage 21 may be formedto include a first extension member 26 located at the first end 22 ofthe passage 21 as best shown in FIG. 3. The knuckle member 12 and thewall defining the passage 21 may also be formed to include a secondextension member 27 located at the second end 23 of the passage 21 asalso shown in FIG. 3. Each extension members 26 and 27 may be unitarywith the knuckle member 12 and further define the passage 21 in theknuckle member 12. The extension members 26 and 27 may be created aspart of the cast forming of the knuckle member 12 and are formed in afirst position wherein the extension members 26 and 27 are aligned with(or extend in) a direction substantially aligned with the center axis Zof the passage 21 of the knuckle member 12 as shown in FIG. 3. Theextension members 26 and 27 have a thickness 28 that is selected suchthat the extension members 26 and 27 may be mechanically formed (e.g.,the parent material of the knuckle member may be rolled, crimped, coldformed or otherwise moved) from the first position to a second positionafter the bushing member 15 has been located in the passage 21. In thesecond position, the extension members 26 and 27 are substantiallyaligned perpendicular with the center axis Z of the passage 21 andsecure the bushing member 15 within the passage 21. In the secondposition, the extension members 26 and 27 define, at least in part, thefirst and second ends 22 and 23 of the passage 21. It should beunderstood that any known or appropriate process may be used for formingor moving the extension members 26 and 27 from the first position (FIGS.3 and 4) to the second position (FIG. 2) such as cold forming, rolling,or any other suitable process that will plastically deform either orboth of the first and second extension members 26 and 27 from the firstposition to the second position and will secure the bushing member 15within the passage 21. While the extension members 26 and 27 are shownas both being cast in the first position, it should be understood thatit is possible to cast the knuckle member 12 with one of the extensionmembers 26 and 27 in the first position and the other in the secondposition so that only one of the extension members 26 and 27 need bemoved to the second position.

The bushing member 15 may have a generally cylindrical shape in that itmay have a generally round cross section. The bushing member 15 mayinclude a first or outer member 16 and a second or inner member 17 asbest shown in FIGS. 2 and 4. The outer member 16 supports the innermember 17 in the passage 21 in the knuckle member 12 as best shown inFIG. 4. The bushing member 15 is for receiving and transferring theforces and moments between the suspension components and may bepress-fit into engagement with the wall defining the passage 21 of theknuckle member 12 and therefore can have some movement within thepassage 21 in response to the forces and movements of the suspensioncomponents. The outer member 16 is preferably made from an elastomericmaterial such as a rubber, or even a natural rubber. The elastomericmaterial of the outer member 16 is selected to exhibit good axial (A)and radial (R) direction stiffness when the bushing member 15 is locatedin the passage 21 as further explained herein. The bushing member 15includes an outer member 16 having a formed or shaped outer surface andincludes a plurality of formed portions for improving the performance ofthe bushing member 12. The outer member 16 is preferably a molded,generally annular member and includes a pair of extensions or ears 18and 19 wherein one ear is located toward each end of the outer member16. The ears 18 and 19 may define a generally scalloped outer surfacestructure for the elastomeric outer member 16. Each ear 18 and 19. is aportion of the outer member 16 that extends substantially radiallyoutward having a given thickness and length for engaging the walldefining the passage 21 of the knuckle member 12 to provide theperformance to the bushing member 15 within the knuckle member 12. Eachear 18 and 19 is defined on each side thereof by at least onevalley-like recess 20 which is a reduced thickness of the outer portion16 which allows the material of the ears 18 and 19 to be compressedwithin the passage 21 and against the ends thereof to affect the axialstiffness of the bushing member 15. The ears 18 and 19, when compressedduring operation, provide substantial axial stiffness to the bushingmember 15 within the passage 21 in the axial (A) direction, andpartially in the radial (R) direction. Further, the recesses 20 on eachside of each ear 18 and 19 provide lower stiffness and therefore greaterflexibility of the bushing member 15 in the conical (C) and torsional(T) directions.

When a force is transferred to the knuckle member 12 through the bushingmember 15, one or more of the ears 18 and 19 will deform about alocation generally within the passage 21 in the knuckle member 12 tochange the shape of the recesses 20 on each side of the ears 18 and 19which is also further defined by the flange F of the outer member 16 andextending along the inner member 17. The co-action of the ear 18 and theflange F imparts additional axial stiffness to the integrated knuckleand bushing assembly 5. At the same time the presence of the recess 20facilitates a generally reduced stiffness of the bushing member 15 inthe conical (C) and torsional (T) directions, as compared with the samestructure and there being no recess. In this manner, it can be seen thatcompeting design tensions may be resolved surprisingly by an elegantlystraightforward design solution.

The inner member 17 of the bushing member 15 may include a shaped bodyfor imparting certain performance characteristics to the bushing member15. The inner member 17 may be made from a metal or steel material suchas cold formed steel having relatively high strength for coupling withthe clevis pin (not shown) and transferring the relatively high loadsassociated with a suspension of a vehicle. Any other known orappropriate material may be used for the inner member 17. The innermember 17 preferably includes a central portion 32 having a generallyrounded or spherical outer periphery 33. The outer periphery 33 may havea generally constant radius but may also have a varying radius foraffecting the performance of the bushing member 15. The inner member 17further includes first and second end portions 34 and 35 extending ingenerally opposite directions along a center or axial axis (I) of theinner member 17. The first and second end portions 34 and 35 of theinner member 17 may have a generally frusto-conical shape wherein thesmaller ends of the substantially conical shapes merge with the outerperiphery 33 of the central portion 32 and the other lager end portionsof the first and second end portions 34 and 35 extend to be aligned withthe first and second ends 22 and 23 of the knuckle member 12. The firstand second end portions 34 and 35 may have a generally round crosssection as taken perpendicular to the central axis I and such roundcross section will have a given radius or diameter. The radius of thecross sections along the first and second end portions 34 and 35 mayvary at a constant, a non-constant or at a zero rate from the centralportion 32 to the first and second ends.

The inner member 17 may include one or more passage, bore, or otherthrough-hole 37 extending along the center axis I through the first andsecond end portions 34 and 35 and the central portion 32. Thethrough-hole 37 may be formed in the inner member 17 when initiallyproducing the inner member 17 or the through-hole 37 may be drilled ormachined through the inner member 17 after the inner member 17 isproduced. Once the inner member 17 is produced, the outer member 16 maybe molded onto the inner member 17. An adhesion promoter such as apotassium-based coating may be applied to the metal inner member 17prior to the inner member 17 being placed in the mold machine and priorto the outer member 16 being molded thereon. The adhesion promoter maybe of any known or appropriate type and is intended to improve theadhesion of the elastomeric material of the outer member 16 to the metalof the inner member 17 such that forces applied to the bushing member 15are effectively transferred between the inner member 17 and outer member16. The inner member 17 (with or without an optional adhesion promoter)may be placed in a mold cavity and the mold closed and then the materialof the outer member 16 may be introduced (e.g., by compression molding,injection-molding, or otherwise) into the mold cavity to form around theinner member and to fill out the mold cavity which produces the outermember having the ears 18 and 19 defined on each side by the recesses20. The bushing member 15 may be produced to have a size that isslightly larger than the size of the passage in the knuckle member 12 sothat the outer member 16 of the bushing member may be compressed orpress-fit within the passage 21 while the first and second extensionportions 26 and 27 of the wall defining the passage 21 are still in thefirst position as best shown in FIG. 4. The bushing member 15 is locatedand aligned within the passage 21 and then the first and secondextension portions 26 and 27 of the wall defining the passage 21 arcformed into their second positions to secure the bushing member 15within the passage 21 as best shown in FIG. 2. It may be appreciatedthat it is also possible to produce the knuckle member 12 only has oneof the first and second extension portions 26 and 27 of the walldefining the passage 21 in the first position and the other of the firstand second extension portions 26 and 27 of the wall defining the passage21 in the second position. In this alternative, the bushing member 15may be inserted or press-fit in the one of the first and secondextension portions 26 and 27 of the wall defining the passage 21 that isin the open position and aligned within the passage 21 and securedtherein by the other of the first and second extension portions 26 and27 of the wall defining the passage 21 that is in the second position.Then, only the one of the first and second extension portions 26 and 27of the wall defining the passage 21 that is in the first position needbe formed to secure the bushing member 15 within the passage 21 of theknuckle member 12.

In addition to the bushing member 15 exhibiting a relatively lowtorsional (T) stiffness and low conical (C) stiffness and a relativelyhigh axial stiffness it may be desirable that the bushing member exhibita relatively high radial (R) stiffness when installed in the passage 21of the knuckle member 12. This may be achieved by shaping anddimensioning at least the central portion 33 of the bushing member 15.Once the bushing member 15 is located, aligned and secured within thepassage 21 of the knuckle member 12, the outer member 16 of the bushingmember 15 may have a thickness D in the area of the central portion 33of the inner member 17 and aligned with central portion 24 of theknuckle member 12 wherein the thickness may be in the range of betweenapproximately two (2 mm) and three (3 mm) millimeters after the knucklemember 15 is located within the passage 21 and the thickness D remainsin the range of between approximately two (2 mm) and three (3 mm)millimeters during operation of integrated knuckle bushing assembly 10in the suspension coupling 5 in the vehicle.

A method for manufacturing integrated knuckle bushing assembly 10 foruse in the suspension assembly 5 includes producing the knuckle member12 having the passage 21 extending there through. The knuckle member 12is preferably produced using a casting process and an aluminum material.The knuckle member 12 is preferably cast having the First extensionmember 26 located at the side 22 of the passage 21 of the knuckle member12. The passage 21 further defines the second extension member 27located at the second side 23 of the passage 21. As best shown in FIG.3, the first and second extension members 26, 27 are shown as initiallyextending in a direction substantially aligned with the axial directionof the passage 21. In one embodiment, one of the first and secondextension members 26, 27 is formed in a closed position such as thatshown in FIG. 4 and the other of the first and second extension members26, 27 is formed in the open position as shown in FIG. 3. As part of themethod, the bushing member 15 is produced having the passage 37extending there through and the plurality of annular reduced portions orrecesses 20 located in the exterior surface of the outer member 16 ofthe bushing member 15. The bushing member 15 is axially aligned in thepassage 21 in the knuckle member 12 by press fitting the bushing member15 in the passage 21 through the end 22. After the bushing member 15 islocated within the knuckle member 12, the first extension member 26 ismoved from the open position shown in FIG. 3 to the closed positionshown in FIG. 4 by rolling or forming the first extension member 26. Thepassage 21 of the knuckle member may be machined to that the wall of thepassage has a relatively smooth finish for receiving the bushing member15.

In producing the bushing member 15, there is first manufactured themetal inner member 17 having the predefined shape as shown in FIGS. 2through 4. The inner member 17 is preferably made using a cold formingprocess appropriate for producing a metal part having the shape anddetails as noted. The passage 37 is formed, such as by drilling alongthe axial center of the inner member 17, using any known or appropriatemanufacturing process. Once the metal inner member 17 is produced, itmay be prepared for receiving the elastomeric material outer member 16such as my preparing the surface of the inner member 17 and applying aphosphate-based primer coating for improving the adhesion of theelastomeric material to the metal. It should be understood that anyknown or appropriate materials and methods for promoting adhesion of theelastomeric outer member 16 to the metal inner member 17 may be usedincluding processes such as blasting and blast coating.

Once the inner member 17 is prepared, it may be located in a mold havingthe shape for forming the outer member 16 including for forming the ears18, 19 and the recesses 20. Once the inner member 17 is located andpositioned in the mold, the elastomeric material may be introduced tothe mold for forming the outer member 16 on the inner member 17. Theelastomeric material may be selected from any known or appropriate groupof elastomeric materials but may be preferably selected from the groupof materials including a synthetic material, a rubber, and a naturalrubber material that is suitable for being over-molded on the innermember 17 and to function as the outer member 16 of the bushing member15. The mold may be used in an injection molding machine (not shown) andthe elastomeric material may he injected into the mold to form the outermember 16 or any other known or appropriate method of molding may beutilized. Once the outer member 16 is formed and sufficiently hardened,the bushing member 15 is formed and may be removed from the mold.

Any numerical values recited herein include all values from the lowervalue to the upper value in increments of one unit provided that thereis a separation of at least 2 units between any lower value and anyhigher value. As an example, if it is stated that the amount of acomponent or a value of a process variable such as, for example,temperature, pressure, time and the like is, for example, from 1 to 90,preferably from 20 to 80, more preferably from 30 to 70, it is intendedthat values such as 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc. areexpressly enumerated in this specification. For values which are lessthan one, one unit is considered to be 0.0001, 0.001, 0.01 or 0.1 asappropriate. These are only examples of what is specifically intendedand all possible combinations of numerical values between the lowestvalue and the highest value enumerated are to be considered to beexpressly stated in this application in a similar manner.

Unless otherwise stated, all ranges include both endpoints and allnumbers between the endpoints. The use of “about” or “approximately” inconnection with a range applies to both ends of the range. Thus, “about20 to 30” is intended to cover “about 20 to about 30”, inclusive of atleast the specified endpoints.

The disclosures of all articles and references, including patentapplications and publications, are incorporated by reference for allpurposes. The term “consisting essentially of” to describe a combinationshall include the elements, ingredients, components or steps identified,and such other elements ingredients, components or steps that do notmaterially affect the basic and novel characteristics of thecombination. The use of the terms “comprising” or “including” todescribe combinations of elements, ingredients, components or stepsherein also contemplates embodiments that consist essentially of orconsist of the elements, ingredients, components or steps.

Plural elements, ingredients, components or steps can be provided by asingle integrated element, ingredient, component or step. Alternatively,a single integrated element, ingredient, component or step might bedivided into separate plural elements, ingredients, components or steps.The disclosure of “a” or “one” to describe an element, ingredient,component or step is not intended to foreclose additional elements,ingredients, components or steps.

It is understood that the above description is intended to beillustrative and not restrictive. Many embodiments as well as manyapplications besides the examples provided will be apparent to those ofskill in the art upon reading the above description. The scope of theinvention should, therefore, be determined not with reference to theabove description, but should instead be determined with reference tothe appended claims, along with the full scope of equivalents to whichsuch claims are entitled. The disclosures of all articles andreferences, including patent applications and publications, areincorporated by reference for all purposes. The omission in thefollowing claims of any aspect of subject matter that is disclosedherein is not a disclaimer of such subject matter, nor should it beregarded that the inventors did not consider such subject matter to bepart of the disclosed inventive subject matter.

1. A knuckle and bushing assembly for use in a suspension system of avehicle, the knuckle and bushing assembly comprising: a knuckle memberhaving a first passage having a first end located at a first side of theknuckle member and a second end located at a second side of the knucklemember, the first passage in the knuckle member having an axial extentdefining a center axis of the passage; a bushing located within andhaving an interference fit with the first passage of the knuckle member,the bushing having a bushing passage extending from a first end of thebushing to a second end of the bushing, the bushing passage defining anaxis being substantially aligned with the axis of the first passage ofthe knuckle member, and the bushing having a first annular reducedportion located in an exterior surface of the bushing; wherein theknuckle member has a first extension member extending at least partiallyin a direction aligned with the center axis of the passage, the firstextension member extending over at least a portion of the first end ofthe bushing and the knuckle member has a second extension memberextending at least partially in a direction aligned with the center axisof the passage, the second extension member extending over at least aportion of the second end of the bushing such that the first and secondextension members of the knuckle member secure the bushing within thefirst passage of the knuckle member.
 2. The knuckle and bushing assemblyof claim 1 wherein the bushing includes a shaped elastomeric body. 3.The knuckle and bushing assembly of claim 1 wherein the bushing includesa molded rubber body.
 4. The knuckle and bushing assembly of claim 1wherein the bushing includes a molded natural rubber body.
 5. Theknuckle and bushing assembly of claim 1 wherein the bushing isconfigured to include a generally circumscribing ear and recessstructure that will deflect in first, second and third directions inresponse to axial, conical and torsional forces applied to the bushingduring operation.
 6. The knuckle and bushing assembly of claim 1 whereinthe ear structure increases the axial stiffness of the bushing while therecess substantially reduces the conical stiffness and the torsionalstiffness of the bushing member.
 7. The knuckle and bushing assembly ofclaim 1 wherein the bushing includes a generally annular intermediateportion having an uncompressed diameter that is larger than the diameterof the first passage in the knuckle member.
 8. The knuckle and bushingassembly of claim 1 wherein the annular intermediate portion when loadedin compression in the passage of the knuckle member has a radial sectionthickness less than or equal to about three millimeters.
 9. The knuckleand bushing assembly of claim 1 wherein the first passage of the knucklemember has an interior wall that includes an arcuate portion in a regionproximate each of the first and second sides of the knuckle member. 10.The knuckle and bushing assembly of claim 5 wherein the ear structureincludes a pair of ears that generally circumscribe the bushing, each ofthe ears having a contoured outer surface defining a generallycircumscribing contoured recessed area between the ears.
 11. The knuckleand bushing assembly of claim 5 wherein the interference fit includes atleast one of the ears contacting the first extension member.
 12. Anintegrated knuckle and bushing assembly for use in a suspension of avehicle, the integrated knuckle and bushing assembly comprising: aknuckle member having a passage extending there through, the knucklemember for providing support for a suspension member; a bushing having apassage extending there through, the bushing being located axiallyaligned in the passage in the knuckle member, the bushing havingplurality of annular reduced portions located in an exterior surface ofthe bushing for providing improved radial, torsional and conical supportto the suspension member to be located within the passage in thebushing; and wherein the knuckle member has a first formed extension ona first side of the passage in the knuckle member and a second formedextension one a second side of the passage in the knuckle member, thefirst and second formed extension members for securing the bushingwithin the passage of the knuckle member.
 13. A method for manufacturingan integrated knuckle and bushing assembly for use in a suspensionassembly in a vehicle, the method comprising the steps of: producing aknuckle member having a passage extending there through, the knucklemember for providing support for a suspension member, the knuckle memberhaving a first extension member located at one end of the passage of theknuckle member and further defining the passage and a second extensionmember located at a second end of the passage of the knuckle member andfurther defining the passage; producing a bushing having a passageextending there through and plurality of annular reduced portionslocated in an exterior surface of the bushing; locating the bushing tobe axially aligned in the passage in the knuckle member, the bushing forproviding improved radial, torsional and conical support to thesuspension member to be located within the passage in the bushing; andforming the first extension member to extend at least partially in adirection aligned with the center axis of the passage and over at leasta portion of the first end of the bushing; and forming the secondextension member to extend at least partially in a direction alignedwith the center axis of the passage and over at least a portion of thesecond end of the bushing to secure the bushing within the passage ofthe knuckle member.
 14. The method for manufacturing an integratedknuckle and bushing assembly of claim 13, wherein the step of producinga knuckle member further comprises the step of casting a knuckle membercomprising aluminum.
 15. The method for manufacturing an integratedknuckle and bushing assembly of claim 13 wherein the step of producing aknuckle member further comprises the step of machining at least onearcuate wall in the first passage prior to the step of forming the firstand second extension members.
 16. The method for manufacturing anintegrated knuckle and bushing assembly of claim 13 wherein the step ofproducing the bushing member includes the steps of producing an innermember having a predefined shape, locating the inner member in a mold,molding an outer member on the inner member, the outer member includinga plurality of extension members for improving the stiffness exhibitedby the bushing member within the passage to exhibit a lower torsionaland conical stiffness while exhibiting a higher radial and axialstiffness.
 17. The method for manufacturing an integrated knuckle andbushing assembly of claim 13 wherein the step of locating the bushingincludes locating the bushing in radial compression within the passageof the knuckle member.
 18. The method for manufacturing an integratedknuckle and bushing assembly of claim 16 wherein the step of forming theinner member includes the step of cold forming the inner member from asteel material, the inner member being formed to have a rounded centerportion and two end portions extending in opposite directions from thecenter portion.
 19. The method for manufacturing an integrated knuckleand bushing assembly of claim 16 wherein the step of forming the innermember includes the step of forming the two end portions of the innermember to have a frusto-conical shape wherein the narrow portion of eachend portion is located proximal the center portion and the broaderportion of each end portion is located distal. the center portion of theinner member.
 20. The method for manufacturing an integrated knuckle andbushing assembly of claim 13 wherein the step of producing the bushingincludes the step of molding an outer member from an elastomericmaterial selected from the group including a synthetic material, arubber, a natural rubber material that is over-molded on an innermember.